Are you looking for something to elevate your product and its packaging to the next level? What if we told you that there is a type of packaging that elevates your brand’s presence on the shelves while also being functional for your products and sustainable for the environment? The packaging we’re referring to is custom pouches.
With the rise in demand for packaged food, businesses are increasingly adopting flexible packaging for their products that cater to cost-effectiveness, sustainability and aesthetic appeal. Pouches are just one type of flexible packaging that’s seen an increase in popularity in recent years, and for good reason.
Pouches are versatile for many industries, such as food, beverage, medical, pharmaceutical, cosmetics, and personal care, with MarketsandMarkets projecting stand-up pouches to dominate the pouch market from to . Stand up pouches for food and drink, in particular, have seen a spike in demand due to their inherent synergies with the products and abundant benefits to the food industry. So, in this guide, we will cover everything you need to know before beginning your pouch packaging project!
The Flexible Packaging Association states that flexible packaging is one of the fastest-growing packaging industry sectors. Additionally, according to a industry report by GlobalData, businesses that switched to stand-up pouches reported a 25% increase in shelf impact and a 30% reduction in packaging costs.
Flexible packaging and, by extension, pouches packaging add value to food and non-food products by combining the best protective qualities of plastic, film, paper, and aluminum foil while using the least amount of materials. Pouches offer:
While the benefits mentioned above can extend to both custom and premade pouches, custom-made pouches offer so much more than stock pouches. Though premade pouches are lower in cost, customization is almost non-existent, a significant disadvantage to your brand in today’s market.
On the other hand, custom stand up pouches are designed from scratch to fit your product and branding requirements. The possibilities are endless, and at PakFactory, you can customize everything from the type of pouch to the materials, coating, layers and features. By developing a unique design that’s pleasing to the eye, convenient, and functional for customers, you are creating a positive image of your brand that will help distinguish you from the competition!
So, with custom pouches in mind, the first thing you can decide is the type of pouch you want for your product. Different pouches have their own set of benefits, but the ability to choose the one that best fits your product is another plus over premade pouches.
Stand up pouch bags are ideal for storing and displaying foods or other retail products. They are one of the main go-to options for flexible packaging and are available in various sub-styles.
The block bottom bag, or flat bottom bag, is a pouch with a flat rectangular base that is sometimes gusseted on the sides, allowing it to stand upright. This pouch offers the maximum balance of stability and presence for your product as it can stand upright on the shelf, has good volume and space for heavier products and features 360 degrees of surface area for custom printing.
Block bottom bags are excellent for products such as coffee, pet food, spices, sweets, frozen foods, nutritional products, household chemicals and high-density products.
Bottom gusset bags are a type of stand-up pouch with a rounded gusset bottom that allows the bag to stand independently without support. They are stronger and hold more weight than block bottom pouches. They are also generally larger than side gusset pouches, allowing more products to be packaged. This pouch type is flexible and suitable for many products, such as snacks, candy, coffee, baking powder, custards, liquids, hygiene products, and medical products.
The three main types of bottom gusset pouches available to you include;
The side gusset is the last sub-style of stand up pouches. As the name suggests, side gusset pouches feature gusseted sides and two flat panels on the front and back, making this style less box-shaped. Side gusset bags take up less space on the shelf but can still hold a good amount of product. Still, their smaller package size makes them more cost-effective, less wasteful, and perfect for storage.
Side gusset bags are popular for snacks, dry ingredients, frozen food, coffee and tea.
A flat pouch, or lay-flat pouch, is a style of flexible pouch packaging that is the most economical out of the other options we will cover in this guide. As the name suggests, lay-flat pouches are designed to lay on the shelf but still offer stability and a large printable surface for customization.
The three main styles available for flat pouches include;
The pillow pouch packaging style is the most common type of flexible packaging. When filled, the pouch expands in the middle and flattens out at the top and bottom seals to resemble a pillow. Pillow pouches are cost-effective, use little space during storage and transport, allow for complete customization on the package’s front and back, and are ideal for single-serve products, snacks, frozen foods, and meal kits.
Pillow pouches also have other optional features, such as press-to-close zippers, hanger holes, product display windows, and tear notches.
Three-sided sealed bags are similar to their four-sided cousin but are sealed on three sides and folded on one. The fold is generally featured on the bottom of the package to allow flexibility and the product to settle at the bottom of the bag, making this pouch ideal for ground products, coffee, snacks, spices, pet food, and produce.
A three-side sealed bag offers the same optional features as the other flat pouch styles while providing more bag volume than the four-side sealed bag and maintaining cost-effectiveness, efficient storage and transportation and good package uniformity for cartoning.
As the name suggests, a four-sided sealed bag is sealed on all sides to provide the best protection against leakage while still being customizable on the front and back panels. Unlike a pillow bag, this flat pouch cannot flex and expand as much, but it is a popular choice for liquid, medical, or sample products.
Four-sided sealed bags are also cost-effective, efficient to store and transport, and offer the same optional features as pillow bags.
Roll stock is a printed and laminated film on a roll that is then used with Form, Fill, Seal (FFS) machinery to form a package, fill it with a product, and seal it. This package option allows brands to create pouches using their own equipment, allowing for high speed and output over long runs.
Roll stock is perfect for smaller items such as nutrition bars, packaged snacks, single-serve samples and stick packs.
Custom shaped pouches offer the ultimate form of customization for your flexible packaging endeavors. If none of the above styles fit your brand’s identity, consider creating a shape that best suits you! Whether you are looking for a standing or flat pouch, you can always customize the bag to suit your desire. From the shape, size and openings to other optional features, a custom shaped pouch is guaranteed to elevate your packaging further.
After deciding on the type of flexible pouch that fits your product, you need to consider the materials you want to use to create it. How pouches are made plays an equally crucial role in your packaging project as the type of pouch you choose, so it is worth considering all the options when making your decision. Some typical pouch materials used include plastic, metal foil, paper, and bioplastics.
Plastic is an excellent barrier against contaminants like oxygen, moisture, dust and UV light. It helps maintain your product’s freshness and has good material qualities like rigidity, stability, flexibility, tensile strength and transparency.
However, plastic has a low melting point and cannot withstand high temperatures. It has a shorter life cycle than containers like glass or metal and is very environmentally harmful, with challenges related to waste, disposal, and recycling.
Plastic materials for pouches are typically made of;
Metal foil provides maximum protection for your product against moisture, light, aromas, and oxygen, extending its shelf life. Foil packaging is durable, resistant to punctures and tears, and can withstand various temperatures.
However, it must be noted that foil still cannot be microwaved and is also harmful to the environment when improperly disposed of. Like plastic, it is non-biodegradable and can take hundreds of years to break down. In addition, foil is more expensive than other materials, such as paper and plastic.
Paper materials are available in natural brown or white kraft. Unlike plastic and foil, kraft stand up pouches are naturally compostable while offering excellent barrier properties that protect a product from spills, pests, UV rays, oxygen, and moisture. Kraft paper also provides a high tensile strength, making the pouch resistant to punctures.
However, though kraft paper offers moisture protection, it still has poor water resistance and strength compared to other materials.
Bioplastics are an environmental alternative to traditional plastics, offering similar protective properties while being less environmentally impactful. Made from plants or other biological materials like polylactic acid (PLA), bioplastic reduces carbon emissions by being biodegradable, breaking down naturally without releasing harmful chemicals. Bioplastics are also resealable, allowing the use of recyclable pouches to further contribute to a sustainable initiative.
However, though bioplastics seem to have all the benefits of plastic without the negatives, this is untrue. Bioplastics generally cost more—though their recyclability somewhat counteracts this—and sometimes have a shorter lifespan than traditional plastics, depending on the type of material used. Also, though bioplastics are biodegradable, they require special facilities and proper disposal to reduce pollution effectively.
We briefly mentioned the optional customization earlier in this guide, but more than a brief mention is needed to show you the breadth of what you can do with a custom pouch. Pouches feature many customizable options, such as various fitments, closures, merchandising features, layers, and shapes.
The first type of customization we will look at are the fitments and closures. These customizations contribute to the longevity of your product by determining how the pouch dispenses your product and whether it can be closed again. Popular options include;
These customization options help display your pouch on store shelves and attract potential customers with convenient additions to your packaging. Options include;
Barrier and coating layers come in direct contact with the product and protect the pouch and its contents against contaminants by providing crucial barrier properties. These customizations improve packaging integrity and structure while increasing shelf life and preventing food waste. Barrier properties for stand-up and flat barrier pouches include;
Typical coating materials to achieve the above barrier properties include aluminum foil, EVOH resin, transparent film, nylon, polyethylene terephthalate (PET), polyethylene (PE), and breathable or permeable barriers.
Goto Renhe to know more.
Pouches typically have multiple layers of material structure, all of which can be customized for different functions to market, protect, and preserve a product. Layers include;
With your packaging customized to your liking, it’s time to consider one of the most crucial factors in your pouch packaging endeavor: how to fill stand-up pouches.
Not only do different treatment and packaging techniques contribute to your product’s ability to maintain taste and freshness while having an optimal shelf life, but they are also crucial to meeting safety, compliance, and quality standards established by regulatory bodies like the FDA.
Standards for product sterility, sterile zones in the manufacturing process, packaging systems, materials and more are all requirements, so carefully considering your treatment and filling methods and ensuring they meet FDA or other regulatory body standards is essential. Common filling and treatment methods include;
The most basic and generally low-cost method of filling involves using a scoop or similar tool to fill a pouch by hand. The bag is then manually sealed using impulse heat-sealing or direct heat-sealing equipment. Manual filling allows greater control over quantity and quality but may only be suitable for small-scale operations or starting businesses, as this is far from ideal at larger scales.
Aseptic packaging is the typical method used in the food and pharmaceutical industry. The product is sterilized through quick exposure to high heat in a technique known as flash pasteurization and then rapidly cooled to room temperature. The product is then filled into sterilized pouches and sealed in a sterile environment, enabling the packaged contents to last up to 18 months.
Ideal applications for aseptic filling include liquid pouch packaging for milk or high-acid products such as juices in glass, aluminum or PET containers.
The retort-filling method involves filling a package with a non-sterile product and sealing it in a non-sterile, retort-able flexible pouch with heat-resistant plastic layers that can withstand high temperatures with or without aluminum foil so the product can be thermo-processed. The retort pouches are then loaded into a retort pressure chamber and sterilized with heated pressurized steam.
Retort pouch packaging is ideal for foods with a pH level greater than or equal to 4.5, such as chicken breasts, chili, ham, and tuna.
The hot-filling process involves sterilizing a product through high heat before filling it into a non-sterile container and immediately cooling it to preserve taste and quality. Opposite to retort packaging, hot-filling is suitable for foods with a pH lower than 4.5 and is also cost-effective for various liquids, including soft drinks, non-carbonated beverages, juices, water, and teas.
The design and print are the final things to consider when planning your pouch project. Depending on the purpose, budget, and type of finish you are looking for, one technique might better suit your needs than the others.
But before we discuss the various techniques available to you, it is important to note that color matching with packages involving two or more components of different materials may be difficult regardless of your chosen printing technique. So, with this in mind, let’s look at the various other pros and cons each printing technique offers.
Flexography is the most commonly used technique for pouch printing and works very well on pouches made of kraft material. It involves rolling the pouch through a printing press and then pulling it into several printing units. Flexography is best for larger runs, as it has high setup costs but has the lowest cost per unit among the other printing options. It offers minimal coloring and lower print qualities unsuitable for photo images but excellent for simple designs and a quick turnaround time.
This printing method works well on a wide selection of materials and involves engraving the image design on multiple color plates and transferring it onto the pouch. Like flexography, rotogravure is best for larger runs with a high setup cost and a lower cost per unit. However, unlike flexography, rotogravure offers crisper colors and exceptional image quality.
The digital printing method involves printing digital-based images directly onto the pouch. This technique is best for smaller runs and dynamic content like special promotions and serialization as it has no setup costs but a higher price per unit. Digital printing offers the fastest turn-around time while having a high print quality and can be used on most materials.
Although this guide contains many factors to consider and may be overwhelming, they are all equally essential to a successful custom pouch project. However, you do not have to work alone. Whether you are looking for more help, are ready to find a pouch packaging manufacturer or partner, or want to jump right in and order custom pouches, PakFactory is the choice for you.
Choosing the right flexible pouch for your product involves a nuanced consideration of your sales channels, competitive landscape, product characteristics, and customer needs. Below, we delve into how these factors influence your packaging decisions, drawing insights from industry best practices and expert advice.
Understanding where your product will be situated in a store is crucial. Whether it’s hanging from a hook or sitting on a shelf impacts the visibility and design requirements of your pouch.
Products placed at eye level might benefit from different features than those stocked higher or lower. The physical placement dictates the design and structural considerations to ensure maximum appeal and practicality.
E-commerce and shipping directly to customers poses another challenge. How to ship your products? Choosing the most efficient pouch size and weight can help to reduce shipping fees and material costs.
Knowing where your competitors are selling their products and the type of pouch they use provides valuable insights. It helps in positioning your product effectively without straying too far from what customers expect in a particular retail space.
Striking the right balance between differentiation and conformity is key. A packaging type that’s too divergent might hinder your chances of securing desirable shelf space.
Another way to stand out would be through your pouch design itself. A high quality design has been proven to attract new customers.
We’re the complete package! Meet your deadlines with ease and efficiency.
Rollstock orders are ready to ship just 10 business days following artwork approval. Formed pouches in 15 days.
Heavier products require sturdy packaging solutions. A plow bottom or K-seal pouch might not offer the needed stability, making flat bottom or quad seal pouches preferable for such items.
Lighter items and pouches with smaller fill weight may not provide the most impactful shelf presence, but may be placed on hooks that are generally at eye level, influencing a potential customer’s purchase decision.
For products intended for multiple uses, the packaging must accommodate this by being resealable. Fin seal or some lay flat pouches may not offer this functionality, affecting consumer convenience and product longevity.
Choosing the right pouch also hinges on your filling process. If automation is your route, the machine’s specifications will likely dictate the pouch types compatible with it. It’s essential to consult with the machine manufacturer to understand any specific pouch requirements. This ensures that the packaging process is seamless and efficient.
On the other hand, manual filling offers the broadest flexibility in pouch selection. This method doesn’t impose machine-related constraints, allowing for a wider variety of pouch types to be considered. Whether opting for an automated system or a manual process, aligning your filling method with your pouch choice is crucial for operational efficiency and product success.
Leveraging the expertise of professionals, like ePac sales representatives, can be invaluable in selecting the optimal pouch type for your product. They can offer tailored advice based on your specific needs and industry trends.
Starting with a no-hassle consultation can demystify the selection process, ensuring your product is packaged in a way that enhances its marketability, preserves its integrity, and meets consumer expectations.
Choosing the right flexible pouch is more than just a packaging decision; it’s a strategic move that can influence your product’s success. Taking a comprehensive approach that considers sales channels, competitive context, product specifics, and professional guidance ensures your packaging decision supports your brand’s overall goals and consumer needs.
Please read this cookie policy (“cookie policy”, "policy") carefully before using the epac.wpengine.com website
(“website”, "service") operated by ePac Holdings, LLC. ("us", 'we", "our").
Cookies are simple text files that are stored on your computer or mobile device by a website’s
server. Each cookie is unique to your web browser. It will contain some anonymous information
such as a unique identifier, website’s domain name, and some digits and numbers.
Necessary cookies allow us to offer you the best possible experience when accessing and
navigating through our website and using its features. For example, these cookies let us
recognize that you have created an account and have logged into that account.
Functionality cookies let us operate the site in accordance with the choices you make. For
example, we will recognize your username and remember how you customized the site during
future visits.
These cookies enable us and third-party services to collect aggregated data for statistical
purposes on how our visitors use the website. These cookies do not contain personal
information such as names and addresses and are used to help us improve your user
experience of the website.
If you want to restrict or block the cookies that are set by our website, you can do so through
your browser setting. Alternatively, you can visit www.internetcookies.com, which contains
comprehensive information on how to do this on a wide variety of browsers and devices. You
will find general information about cookies and details on how to delete cookies from your
device.
If you have any questions about this policy or our use of cookies, please contact us.
For more information, please visit Packaging Pouch Manufacturer.